Fuel Tank, Draining When Less Than 3/4 Full, FWD: Notes

WARNING: This page is about a different car, the 2015 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Wrench - Fuel Sending Unit:T10202
Torque Wrench 1332 40-200 Nm :VAG1332
Trim Removal Wedge:3409
Fuel Extractor VAS5190A:VAS5190

WARNING:

To prevent large quantities of fuel from leaking from the fuel delivery unit when removing, the fuel tank may only be a maximum of ¹ /₃ full.

-- Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to PARKING/AUXILIARY HEATER AND FUEL SYSTEM CLEAN WORKING CONDITIONS .

-- Remove the rear bench seat. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Unclip the right locking flange cover -1- at the tabs in direction of -arrows- using the :3409 .

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-- Unclip the grommet -1- downward out of the cover -2-.

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-- Guide the cover -2- on the wiring harness -3- downward.

-- Unlock and disconnect the connectors -1 and 2- from the locking flange.

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Vehicles With Parking Heater (CANADA ONLY):

-- Release the connector -3- for the Metering Pump -V54- and disengage it from the sealing flange.

-- Release the connector -3- for the Metering Pump -V54- and remove it.

Continuation For All Vehicles

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-- Lift the tab -2- in direction of -arrow A-.

-- To do so, reach between the floor panel and the fuel tank with a finger.

-- At the same time, pull the Fuel Pump Control Module -J538- -1- on the wiring harness -3- in direction of -arrow B- carefully out of the mount.

-- Remove the Fuel Pump Control Module -J538- toward the inside between the fuel tank and the floor panel.

-- Move the Fuel Pump Control Module -J538- together with the wiring harness to the side.

-- Remove the fuel line -1- from the locking flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

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WARNING:

Fuel Lines Are Under Pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

-- Remove the fuel return line -2- from the locking flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Vehicles With Parking Heater (CANADA ONLY):

-- Remove the fuel line -3- to the Metering Pump -V54- for the parking heater on the locking flange.

-- Open the lower clamp to do this.

-- Remove the fuel line -3- carefully.

Continuation For All Vehicles:

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-- Open the locking ring with :T10202 .

-- Carefully lift the fuel delivery unit flange -3-.

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-- Remove the seal -1- and carefully raise the flange on the fuel delivery unit higher.

CAUTION:

Attach the :VAS5190 Ground (GND) cable to an ungrounded area on the body.

-- Insert the suction hose for the :VAS5190 as deep as possible into the fuel tank.

-- Extract the fuel using the :VAS5190 .

Install the fuel delivery unit again if the fuel tank is only being emptied. Refer to FUEL DELIVERY UNIT/FUEL LEVEL SENSOR, REMOVING AND INSTALLING .